Integrated additive manufacturing systems incorporating a fixturing apparatus

ABSTRACT

An integrated additive manufacturing system includes: (a) at least one resin supply (41); (b) a plurality of additive manufacturing machines (43) on which parts may be produced, each of said additive manufacturing machines (43) operatively associated with said at least one resin supply (41); and (c) at least one peripheral machine operatively associated with each of said additive manufacturing machines and said at least one resin supply, wherein said at least one peripheral machine comprises a part fixturing apparatus (200).

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application Ser.No. 62/471,675, filed Mar. 15, 2017, U.S. Provisional Application Ser.No. 62/506,247, filed May 15, 2017, and U.S. Provisional ApplicationSer. No. 62/596,952, filed Dec. 11, 2017, the disclosures of which arehereby incorporated by reference in their entirety.

TECHNICAL FIELD

The present invention concerns additive manufacturing, and particularlyconcerns methods, apparatus, and systems for additive manufacturing inwhich multiple operations are performed in an integrated fashion.

BACKGROUND

The production of three-dimensional objects from polymerizable resins bystereolithography has been known for some time (see, e.g., U.S. Pat. No.5,236,637 to Hull). Unfortunately, such techniques have been generallyconsidered slow, and are typically limited to resins that producebrittle or fragile objects suitable only as prototypes. A more recenttechnique known as continuous liquid interface production (CLIP) allowsboth more rapid production of objects by stereolithography (see, e.g.,U.S. Pat. No. 9,205,601 to DeSimone et al.), and the production of partswith isotropic mechanical properties (see R. Janusziewcz et al.,Layerless fabrication with continuous liquid interface production, Proc.Natl. Acad. Sci. USA 113, 11703-11708, Oct. 18, 2016). Along with themore recent introduction of a variety of different dual cure resins forstereolithography (particularly CLIPs; see, e.g., U.S. Pat. No.9,453,142 to Rolland et al.), these developments make possible theproduction of a much greater variety of functional, useful, objectssuitable for real world use.

Current systems for additive manufacturing tend to be tailored towardsprototyping—the making of small numbers of models that can be used todecide whether to invest in a high-volume manufacturing technique likeinjection molding—rather than towards the larger volume of real-worldparts themselves. Accordingly, there is a need for new systems whichmake possible higher volume production of functional parts by additivemanufacturing.

SUMMARY

Some embodiments of the invention are directed to an integrated additivemanufacturing system, including: (a) at least one resin supply; (b) aplurality of additive manufacturing machines on which parts may beproduced, each of the additive manufacturing machines operativelyassociated with the at least one resin supply; and (c) at least oneperipheral machine operatively associated with each of the additivemanufacturing machines and the at least one resin supply.

In some embodiments, the at least one resin supply includes a single-use(e.g., cartridge) resin supply or a bulk resin supply, each of which canbe associated with either one of or a plurality of the additivemanufacturing machines, and each of which can optionally include anautomated resin feed system configured to supply resin to one of, or aplurality of, the additive manufacturing machines.

In some embodiments, the at least one peripheral machine includes: atleast one part post-production machine, such as at least one of a partwashing machine, a part penetrant bath apparatus (e.g. for impregnatingan additional polymerizable component into a part after additivemanufacturing but before further or subsequent cure), a part oven, apart cutting, grinding, and/or texturing machine (e.g., bead blasting,milling, tumbling, etc.), a part painting machine, or a combinationthereof; and/or at least one maintenance machine configured to maintainor replace a component of the additive manufacturing machines, such as abuild plate (or “window”) cleaning machine (for example, when theadditive manufacturing machines each include an optically transparentbuild plate, configured to be releasably secured to the additivemanufacturing machine).

In some embodiments, the at least one peripheral machine includes a partwashing machine.

In some embodiments, the system further includes: (d) a databaseoperatively associated with each of the plurality of additivemanufacturing machines, the database configured to record partconfiguration data for each part produced on each additive manufacturingmachine.

The database may be further configured to contain specific resin datafor each of a plurality of different resins. The at least one resinsupply may include a resin container (e.g., a bulk container or a singleuse container) having a resin therein and a resin unique identifier(e.g., a bar code) operatively associated therewith, with the resinunique identifier associated with specific resin data for the containedresin. Each of said plurality of additive manufacturing machines mayinclude a resin unique identifier reader operatively associatedtherewith and a resin reservoir configured to receive resin from theresin container. Each of the plurality of additive manufacturingmachines may be configured to carry out a part production process withsaid resin based on both part configuration data (e.g., an .stl file)and the specific resin data.

Each of the additive manufacturing machines may include a releasablecarrier plate on which a part is produced from the resin, with each ofthe carrier plates having a carrier plate unique identifier (e.g., anNFC tag) operatively associated therewith. The database may be furtherconfigured to record both part configuration data and resin data, andoptionally but preferably time of production, for each part produced oneach carrier plate. The part washing machine may include a carrier plateunique identifier reader operatively associated therewith. The partwashing machine may be configured to select and carry out a part washingprocess on each part from a plurality of different part washingprocesses (optionally but preferably while each part remains on thecarrier plate on which the part was produced) based on: (i) partconfiguration data, (ii) specific resin data, or (iii) both partconfiguration data and specific resin data. The database may optionallybut preferably be configured to record washing process data, andoptionally but preferably time of wash, for each part washed in the partwashing machine.

In some embodiments, at least one of the peripheral machines (e.g., thepart washing machine) is configured to releasably secure said carrierplate.

In some embodiments, the system further includes: (e) an ovenoperatively associated with each additive manufacturing machine. Theoven may be optionally configured to select and carry out a bakingprocess on each part from a plurality of different baking processes(optionally but preferably while each part remains on the carrier plateon which the part was produced) based on: (i) part configuration data,(ii) specific resin data, or (iii) both part configuration data andspecific resin data. The database may be optionally but preferablyconfigured to record baking process data, and optionally but preferablytime of bake, for each part baked in the oven.

In some embodiments, each of the additive manufacturing machines isconfigured to apply a part unique identifier (e.g., an alphanumericidentifier) to each part produced thereon. The database further may beconfigured to record the part unique identifier from each of theadditive manufacturing machines.

In some embodiments, each of the additive manufacturing machinesincludes an interchangeable build plate, with the build plate includingan optically transparent member and a build plate unique identifier(e.g., a second NFC tag). Each of the plurality of additivemanufacturing machines may further include a build plate uniqueidentifier reader. The database may be further configured to recordbuild plate data for each part produced on each of the plurality ofadditive manufacturing machines.

In some embodiments, the system further includes a curing apparatusconfigured to cure (preferably by heating) said composite articles, withsaid first part and said additional part pressed against one anotherduring said curing with force sufficient to adhere one to the other.

In some embodiments, said first part is reshaped during by the curingoperation of the curing apparatus.

Some other embodiments of the invention are directed to an integratedmethod for producing and washing parts by additive manufacturing,including: (a) providing a manufacturing system including a plurality ofadditive manufacturing machines operatively associated with a partwashing machine, with the part washing machine configured to execute aplurality of different wash programs; (b) generating at least one parton each of the plurality of additive manufacturing machines to produce abatch of parts to be washed, each part of the batch produced from aresin and from part configuration data, and with each part havingresidual resin thereon; and (c) washing each of the plurality of partsin the part washing machine with the same wash liquid in a plurality ofconsecutive wash programs for each part, each wash program configured orselected based on: (i) part configuration data, (ii) specific resindata, or (iii) both part configuration data and specific resin data; (d)optionally, but in some embodiments preferably, fixing each saidplurality of parts as a first part to a respective additional part toform a composite article of each thereof; and then (e) optionally, butpreferably, further curing (e.g., by heating) each of said plurality ofparts.

In some embodiments, each part is produced in step (b) on a carrierplatform that includes a carrier unique identifier (e.g., a bar code,NFC tag or RFID tag), and each washing step is carried out with the parton the carrier platform on which it was produced, and the wash programis configured or selected based upon information associated with saidcarrier unique identifier.

In some embodiments, each of the consecutive wash programs for each partis carried out in a total time of not more than 1, 2, 5 or 10 minutes.In some embodiments, each wash program for each part is carried out in asequence of (i) agitating (e.g., spinning) the part in wash liquid, (ii)separating or draining wash liquid from the part, (iii) agitating (e.g.,spinning) the part free of wash liquid to further separate residualresin; and (iv) optionally but preferably repeating steps (i) through(iii) at least once, all optionally but preferably in the same vessel,and all optionally with the same wash liquid.

In some embodiments, the residual resin has a boiling point of at least90 or 100° C. (e.g., up to 250 or 300° C., or more), and the wash liquidhas a boiling point of from 30° C. to 80 or 90° C.

In some embodiments, the wash liquid includes an organic solvent (e.g.,a halogenated organic solvent, such as a fluorinated organic solvent, asiloxane solvent, etc.). The organic solvent may include an azeotropicmixture comprised of at least a first organic solvent (e.g., ahydrofluorocarbon solvent, a hydrochlorofluorocarbon solvent, ahydrofluorether solvent, a methylsiloxane solvent, or a combinationthereof; e.g., in an amount of from 80 or 85 to 99 percent by weight)and a second organic solvent (e.g., a C1-C4 or C6 alcohol such asmethanol, ethanol, isopropanol, tert-butanol, etc.; e.g., in an amountof from 1 to 15 or 20 percent by weight).

In some embodiments, the method includes recording at least one, anycombination, or all of wash liquid type, wash liquid batch, wash liquidusage history, day of wash, time of day of wash, wash machine identity,wash liquid temperature, wash program, interval between additiveproduction and wash, and/or wash machine operator, in association witheach part (e.g., through a unique identifier on or associated with eachpart, and a unique identifier reader associated with said part washingmachine).

Some other embodiments of the invention are directed to an integratedmethod for producing and baking parts by additive manufacturing,including: (a) providing a manufacturing system including a plurality ofadditive manufacturing machines operatively associated with an oven, andoptionally with a part washing machine, with the oven configured toexecute a plurality of different bake programs; (b) generating at leastone part on each of the plurality of additive manufacturing machines toproduce a batch of parts to optionally be washed, each part of the batchproduced from a resin and from part configuration data; (c) optionallywashing each of the plurality of parts in the part washing machine; (d)optionally, but in some embodiments preferably, fixing each saidplurality of parts as a first part to a respective additional part toform a composite article of each thereof; and then (e) baking each ofthe plurality of parts, sequentially or simultaneously in the oven, witheach of the parts baked in accordance with a bake program selected orconfigured based on (i) part configuration data, (ii) specific resindata, or (iii) both part configuration data and specific resin data.

In some embodiments, the step of washing each of the plurality of partsis included and carried out with the same wash liquid in accordance witha plurality of consecutive wash programs for each part, each washprogram selected or configured based on: (i) part configuration data,(ii) specific resin data, or (iii) both part configuration data andspecific resin data.

In some embodiments, the oven includes a batch oven (optionallyincluding a lock assembly and/or an alarm, and the baking stepoptionally further includes locking said oven for the duration of saidbake program, and/or activating said alarm upon deviation by the ovenfrom the bake program).

In some embodiments, the oven includes a continuous process (e.g.,conveyor) oven (optionally including a temperature monitor, and the ovenoptionally includes a shut-down and/or alarm configured to operate upondeviation by the oven from the bake program).

In some embodiments, the method includes recording at least one, anycombination, or all of oven identity, bake program, day of bake, time ofday of bake, and/or oven operator, interval between additive productionand bake, and/or interval between wash and bake, and/or wash machineoperator, in association with each part (e.g., through a uniqueidentifier on or associated with each part, and a unique identifierreader associated with the oven).

Some other embodiments of the invention are directed to a method oftracking production of parts from a resin, including: (a) providing adatabase including resin data, the resin data including: (i) at leastone resin type data, and (ii) resin batch data for each of a pluralityof batches of each resin type; (b) producing a plurality of parts fromone resin type and from part configuration data (e.g., an .stl file)with at least one additive manufacturing machine by a part productionprocess, each of the parts having a part unique identifier appliedthereto; (c) generating in the database a part record for each of theparts, the part record including resin type data, resin batch data, partproduction process data, and part unique identifier, the part recordoptionally including or excluding part configuration data.

In some embodiments, the method further includes the step of: (d)washing each part in a washing machine with a wash liquid in accordancewith a wash cycle, and also adding wash cycle data and wash liquid datato each part record for each part washed.

In some embodiments, the method further includes the step of: (f) bakingeach part in an oven in accordance with a bake cycle and also addingbake cycle data to each part record for each part baked.

In some embodiments, the method includes generating a report from thedatabase for at least one selected part based on said part uniqueidentifier, said report including, for each selected part, at least one,or any combination, or all of: (i) resin type data, resin batch data,resin manufacturer identity; and/or (ii) part configuration data, partproduction program data, part production machine identity, build plateidentity, time of part production, interval between resin manufactureand part production, interval between resin dispensing (and/or blending,for example for dual precursor resins) and part production, partproduction machine operator identity; and/or (iii) wash program data,wash liquid data, wash liquid batch, wash machine identity, time ofwash, interval between time of production and time of wash, wash machineoperator identity; and/or (iv) bake program data, time of bake, ovenidentity, interval between wash and bake, interval between additiveproduction and bake, and/or oven operator identity.

In some embodiments, the method includes generating a report from thedatabase for all parts sharing at least one, or any combination of, orall of, the same: (i) resin type data, resin batch data, resinmanufacturer identity; and/or (ii) part configuration data, partproduction program data, part production machine identity, build plateidentity, time of part production, interval between resin manufactureand part production, interval between resin dispensing (and/or blending,for example for dual precursor resins) and part production, partproduction machine operator identity; and/or (iii) wash program data,wash liquid data, wash liquid batch, wash machine identity, time ofwash, interval between time of production and time of wash, wash machineoperator identity; and/or (iv) bake program data, time of bake, ovenidentity, interval between wash and bake, interval between additiveproduction and bake, and/or oven operator identity.

Also described herein is a method of making a composite article byadditive manufacturing, comprising: (a) producing a first part from adual cure resin by additive manufacturing (e.g., by stereolithography,preferably by continuous liquid interface production); (b) washing thefirst part with a solvent (e.g., an organic solvent); then (c) fixingthe first part to an additional part to form a composite article; andthen (d) further curing, preferably by baking, the composite article,with the first part and the additional part pressed against one anotherduring the further curing step with force sufficient to adhere each tothe other.

Some other embodiments of the invention are directed to an integratedadditive manufacturing system comprising: a processor; a data repositorycomprising a database configured to record part configuration data for apart produced by the integrated additive manufacturing system; anadditive manufacturing machine configured to manufacture a part throughadditive manufacturing; and a memory coupled to the processor andcomprising computer readable program code that when executed by theprocessor causes the processor to perform operations comprising:obtaining a part image sequence comprising instructions for additivelymanufacturing the part on the additive manufacturing system; generatinga unique identifier associated with the part; and modifying the partimage sequence to create a merged image sequence comprising instructionsfor generating a manufactured part on the additive manufacturing machinewith a representation of the unique identifier contained on or withinthe manufactured part.

In some embodiments, the unique identifier includes alphanumericcharacters and/or symbols.

In some embodiments, the operations further include obtaining a uniqueidentifier image sequence comprising instructions for additivelymanufacturing the representation of the unique identifier on theadditive manufacturing system, and modifying the part image sequence tocreate the merged image sequence includes merging the part imagesequence and the unique identifier image sequence.

In some embodiments, the operations further include storing the uniqueidentifier in the database.

In some embodiments, the operations further include manufacturing thepart on the additive manufacturing machine using the merged imagesequence.

In some embodiments, the operations further include storing partconfiguration data associated with the manufacturing of the part in thedatabase.

In some embodiments, the part configuration data associated with themanufacturing of the part in the database includes resin data associatedwith a resin used to manufacture the part.

In some embodiments, the system includes a camera configured tooptically capture the unique identifier contained on or within themanufactured part.

In some embodiments, the system includes a part washing machine, and thepart washing machine is configured to select a wash program for themanufactured part based on the unique identifier associated with thepart.

In some embodiments, the part configuration data contained in thedatabase further includes wash data associated with the wash programused by the part washing machine.

In some embodiments, the system includes a curing machine, and thecuring machine is configured to select a cure program for themanufactured part based on the unique identifier associated with thepart.

In some embodiments, the part configuration data contained in thedatabase further includes cure data associated with the cure programused by the curing machine.

In some embodiments, the manufactured part is a first manufactured part,the merged image sequence is a first merged image sequence, the uniqueidentifier is a first unique identifier, and the operations furtherinclude: generating a second unique identifier associated with the part;and modifying the part image sequence to create a second merged imagesequence, different from the first merged image sequence, said secondmerged image sequence comprising instructions for generating a secondmanufactured part on the additive manufacturing machine with arepresentation of the second unique identifier contained on or withinthe second manufactured part.

In some embodiments, the operations further include: associating a buildplate identity of a build plate used to manufacture the part with theunique identifier associated with the part; and storing the build plateidentity in the database.

Also described herein is a part manufactured using the integratedadditive manufacturing system of the embodiments described herein.

Also described herein is a manufactured part including anadditively-manufactured portion, wherein the additively-manufacturedportion includes a unique identifier structurally incorporated into theadditively-manufactured portion.

Further aspects of the present invention are explained in greater detailin the drawings herein and the specification below. The disclosures ofall United States Patent references cited herein are to be incorporatedherein by reference in their entirety.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A schematically illustrates one embodiment of a process of thepresent invention.

FIG. 1B schematically illustrates a portion of a second embodiment of aprocess of the present invention, similar to that of FIG. 1A, but nowincluding a fixturing station.

FIG. 2A lists one example of various different resin types that may berecorded in carrying out the present invention.

FIG. 2B lists one example of resin batch data that may be recorded incarrying out the present invention.

FIG. 2C lists one example of resin dispense data that may be recorded incarrying out the present invention.

FIG. 3 lists one example of additive manufacture production data thatmay be recorded in carrying out the present invention.

FIG. 4A is a flow chart schematically illustrating one process ofassigning and generating an individual object with a unique identifierfor that object, by additive manufacturing.

FIG. 4B is a flow chart of a particular embodiment of FIG. 4A.

FIG. 5 is a non-limiting example of different wash program options thatmay be carried out, and recorded, in the present invention.

FIG. 6 lists one example of wash step data that may be recorded incarrying out the present invention.

FIG. 7 is a non-limiting example of different further cure (bake)program options that may be carried out, and recorded, in the presentinvention.

FIG. 8 lists one example of cure step data that may be recorded incarrying out the present invention.

FIG. 9A schematically illustrates one embodiment of an integrated systemof the present invention.

FIG. 9B is a detailed view of the portion ‘A’ of FIG. 9A shown in thedashed box, further illustrating an oxygen supply and barometricsensing/atmospheric pressure sensing features.

FIG. 10 schematically illustrates a second embodiment of an integratedsystem of the present invention.

FIG. 11 schematically illustrates multiple integrated systems which arefurther integrated with one another in one embodiment of the presentinvention.

FIG. 12 schematically illustrates one example of a tracking report foran object, generated in accordance with the present invention.

FIG. 13 schematically illustrates one example of a fixturing station ofthe present invention, in which a pre-formed component is fixed orjoined to the additively manufactured component, before or after wash,preferably after wash, and preferably before heat cure of the additivelymanufactured component in an oven.

FIG. 14 schematically illustrates one example of an automated supportremoval station suitable for use in the systems of the presentinvention, in which station a tool mounted on a robotic arm removessupports based on known locations and characteristics of those supports.

DETAILED DESCRIPTION

The present invention is now described more fully hereinafter withreference to the accompanying drawings, in which embodiments of theinvention are shown. This invention may, however, be embodied in manydifferent forms and should not be construed as limited to theembodiments set forth herein; rather these embodiments are provided sothat this disclosure will be thorough and complete and will fully conveythe scope of the invention to those skilled in the art.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention. Asused herein, the singular forms “a,” “an” and “the” are intended toinclude plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprises” or“comprising,” when used in this specification, specify the presence ofstated features, integers, steps, operations, elements components and/orgroups or combinations thereof, but do not preclude the presence oraddition of one or more other features, integers, steps, operations,elements, components and/or groups or combinations thereof.

As used herein, the term “and/or” includes any and all possiblecombinations or one or more of the associated listed items, as well asthe lack of combinations when interpreted in the alternative (“or”).

Unless otherwise defined, all terms (including technical and scientificterms) used herein have the same meaning as commonly understood by oneof ordinary skill in the art to which this invention belongs. It will befurther understood that terms, such as those defined in commonly-useddictionaries, should be interpreted as having a meaning that isconsistent with their meaning in the context of the specification andclaims and should not be interpreted in an idealized or overly formalsense unless expressly so defined herein. Well-known functions orconstructions may not be described in detail for brevity and/or clarity.

It will be understood that when an element is referred to as being “on,”“attached” to, “connected” to, “coupled” with, “contacting,” etc.,another element, it can be directly on, attached to, connected to,coupled with and/or contacting the other element or intervening elementscan also be present. In contrast, when an element is referred to asbeing, for example, “directly on,” “directly attached” to, “directlyconnected” to, “directly coupled” with or “directly contacting” anotherelement, there are no intervening elements present. It will also beappreciated by those of skill in the art that references to a structureor feature that is disposed “adjacent” another feature can have portionsthat overlap or underlie the adjacent feature.

Spatially relative terms, such as “under,” “below,” “lower,” “over,”“upper” and the like, may be used herein for ease of description todescribe an element's or feature's relationship to another element(s) orfeature(s) as illustrated in the figures. It will be understood that thespatially relative terms are intended to encompass differentorientations of the device in use or operation in addition to theorientation depicted in the figures. For example, if the device in thefigures is inverted, elements described as “under” or “beneath” otherelements or features would then be oriented “over” the other elements orfeatures. Thus the exemplary term “under” can encompass both anorientation of over and under. The device may otherwise be oriented(rotated 90 degrees or at other orientations) and the spatially relativedescriptors used herein interpreted accordingly. Similarly, the terms“upwardly,” “downwardly,” “vertical,” “horizontal” and the like are usedherein for the purpose of explanation only, unless specificallyindicated otherwise.

It will be understood that, although the terms first, second, etc., maybe used herein to describe various elements, components, regions, layersand/or sections, these elements, components, regions, layers and/orsections should not be limited by these terms. Rather, these terms areonly used to distinguish one element, component, region, layer and/orsection, from another element, component, region, layer and/or section.Thus, a first element, component, region, layer or section discussedherein could be termed a second element, component, region, layer orsection without departing from the teachings of the present invention.The sequence of operations (or steps) is not limited to the orderpresented in the claims or figures unless specifically indicatedotherwise.

1. Polymerizable Liquids (Resins).

Numerous resins for use in additive manufacturing are known and can beused in carrying out the present invention. See, e.g., U.S. Pat. No.9,205,601 to DeSimone et al. Indeed, a feature of the present inventionis to accommodate the potential use of different resins in a singleadditive manufacturing system.

In some embodiments, the additive manufacturing step is formed from adual cure resin. Such resins are described in, for example, J. Rollandet al., PCT Applications PCT/US2015/036893 (see also US PatentApplication Pub. No. US 2016/0136889), PCT/US2015/036902 (see also USPatent Application Pub. No. US 2016/0137838), PCT/US2015/036924 (seealso US Patent Application Pub. No. US 2016/0160776), andPCT/US2015/036946 (see also U.S. Pat. No. 9,453,142).

Resins may be in any suitable form, including “one pot” resins and “dualprecursor” resins (where cross-reactive constituents are packagedseparately).

Particular examples of suitable resins include, but are not limited to,Carbon, Inc. rigid polyurethane resin (RPU), flexible polyurethane resin(FPU), elastomeric polyurethane resin (EPU), cyanate ester resin (CE),epoxy resin (EPX), or urethane methacrylate resin (UMA), all availablefrom Carbon, Inc., 1089 Mills Way, Redwood City, Calif. 94063 USA.

Note that, in some embodiments employing “dual cure” polymerizableresins, the part, following manufacturing, may be contacted with apenetrant liquid, with the penetrant liquid carrying a furtherconstituent of the dual cure system, such as a reactive monomer, intothe part for participation in a subsequent cure.

2. Additive Manufacturing Methods and Apparatus.

The three-dimensional intermediate to be washed is preferably formedfrom polymerizable resins by additive manufacturing, typically bottom-upor top-down additive manufacturing, generally known asstereolithography. Such methods are known and described in, for example,U.S. Pat. No. 5,236,637 to Hull, U.S. Pat. Nos. 5,391,072 and 5,529,473to Lawton, U.S. Pat. No. 7,438,846 to John, U.S. Pat. No. 7,892,474 toShkolnik, U.S. Pat. No. 8,110,135 to El-Siblani, US Patent ApplicationPublication No. 2013/0292862 to Joyce, US Patent Application PublicationNo. 2013/0295212 to Chen et al., and M. Shusteff et al., One-stepvolumetric additive manufacturing of complex polymer structures, ScienceAdvances (published December 2017). The disclosures of these patents,applications, and publication are incorporated by reference herein intheir entirety.

In general, top-down three-dimensional fabrication is carried out by:

(a) providing a polymerizable liquid reservoir having a polymerizableliquid fill level and a carrier positioned in the reservoir, the carrierand the fill level defining a build region therebetween;

(b) filling the build region with a polymerizable liquid (i.e., theresin), said polymerizable liquid comprising a mixture of (i) a light(typically ultraviolet light) polymerizable liquid first component, and(ii) a second solidifiable component of the dual cure system; and then

(c) irradiating the build region with light to form a solid polymerscaffold from the first component and also advancing (typicallylowering) the carrier away from the build surface to form athree-dimensional intermediate having the same shape as, or a shape tobe imparted to, the three-dimensional object and containing said secondsolidifiable component (e.g., a second reactive component) carried inthe scaffold in unsolidified and/or uncured form.

A wiper blade, doctor blade, or optically transparent (rigid orflexible) window, may optionally be provided at the fill level tofacilitate leveling of the polymerizable liquid, in accordance withknown techniques. In the case of an optically transparent window, thewindow provides a build surface against which the three-dimensionalintermediate is formed, analogous to the build surface in bottom-upthree-dimensional fabrication as discussed below.

In general, bottom-up three-dimensional fabrication is carried out by:

(a) providing a carrier and an optically transparent member having abuild surface, the carrier and the build surface defining a build regiontherebetween;

(b) filling the build region with a polymerizable liquid (i.e., theresin), said polymerizable liquid comprising a mixture of (i) a light(typically ultraviolet light) polymerizable liquid first component, and(ii) a second solidifiable component of the dual cure system; and then

(c) irradiating the build region with light through said opticallytransparent member to form a solid polymer scaffold from the firstcomponent and also advancing (typically raising) the carrier away fromthe build surface to form a three-dimensional intermediate having thesame shape as, or a shape to be imparted to, the three-dimensionalobject and containing said second solidifiable component (e.g., a secondreactive component) carried in the scaffold in unsolidified and/oruncured form.

In some embodiments of bottom-up or top-down three-dimensionalfabrication as implemented in the context of the present invention, thebuild surface is stationary during the formation of thethree-dimensional intermediate; in other embodiments of bottom-upthree-dimensional fabrication as implemented in the context of thepresent invention, the build surface is tilted, slid, flexed and/orpeeled, and/or otherwise translocated or released from the growingthree-dimensional intermediate, usually repeatedly, during formation ofthe three-dimensional intermediate.

In some embodiments of bottom-up or top-down three-dimensionalfabrication as carried out in the context of the present invention, thepolymerizable liquid (or resin) is maintained in liquid contact withboth the growing three-dimensional intermediate and the build surfaceduring both the filling and irradiating steps, during fabrication ofsome of, a major portion of, or all of the three-dimensionalintermediate.

In some embodiments of bottom-up or top-down three-dimensionalfabrication as carried out in the context of the present invention, thegrowing three-dimensional intermediate is fabricated in a layerlessmanner (e.g., through multiple exposures or “slices” of patternedactinic radiation or light) during at least a portion of the formationof the three-dimensional intermediate.

In some embodiments of bottom-up or top-down three-dimensionalfabrication as carried out in the context of the present invention, thegrowing three-dimensional intermediate is fabricated in a layer-by-layermanner (e.g., through multiple exposures or “slices” of patternedactinic radiation or light), during at least a portion of the formationof the three-dimensional intermediate.

In some embodiments of bottom-up or top-down three-dimensionalfabrication employing a rigid or flexible optically transparent window,a lubricant or immiscible liquid may be provided between the window andthe polymerizable liquid (e.g., a fluorinated fluid or oil such as aperfluoropolyether oil).

From the foregoing it will be appreciated that, in some embodiments ofbottom-up or top-down three-dimensional fabrication as carried out inthe context of the present invention, the growing three-dimensionalintermediate is fabricated in a layerless manner during the formation ofat least one portion thereof, and that same growing three-dimensionalintermediate is fabricated in a layer-by-layer manner during theformation of at least one other portion thereof. Thus, operating modemay be changed once, or on multiple occasions, between layerlessfabrication and layer-by-layer fabrication, as desired by operatingconditions such as part geometry.

In some embodiments, the intermediate is formed by continuous liquidinterface production (CLIP). CLIP is known and described in, forexample, PCT Application Nos. PCT/US2014/015486 (published as U.S. Pat.No. 9,211,678 on Dec. 15, 2015); PCT/US2014/015506 (also published asU.S. Pat. No. 9,205,601 on Dec. 8, 2015), PCT/US2014/015497 (alsopublished as U.S. Pat. No. 9,216,546 on Dec. 22, 2015), A. Ermoshkin etal., Three-dimensional printing with reciprocal feeding of polymerizableliquid, PCT/US2015/195924 (also published as US Patent Application Pub.No. US 2017/0173871 on Jun. 22, 2017); P. Sutter et al., Fabrication ofthree dimensional objects with multiple operating modes,PCT/US2016/140886 (also published as US Patent Application Pub. No.US20180022034 on Jan. 25, 2018) and in J. Tumbleston, D. Shirvanyants,N. Ermoshkin et al., Continuous liquid interface production of 3DObjects, Science 347, 1349-1352 (published online 16 Mar. 2015). In someembodiments, CLIP employs features of a bottom-up three-dimensionalfabrication as described above, but the irradiating and/or saidadvancing steps are carried out while also concurrently maintaining astable or persistent liquid interface between the growing object and thebuild surface or window, such as by: (i) continuously maintaining a deadzone of polymerizable liquid in contact with said build surface, and(ii) continuously maintaining a gradient of polymerization zone (such asan active surface) between the dead zone and the solid polymer and incontact with each thereof, the gradient of polymerization zonecomprising the first component in partially cured form. In someembodiments of CLIP, the optically transparent member comprises asemipermeable member (e.g., a fluoropolymer), and the continuouslymaintaining a dead zone is carried out by feeding an inhibitor ofpolymerization through the optically transparent member, therebycreating a gradient of inhibitor in the dead zone and optionally in atleast a portion of the gradient of polymerization zone. Other approachesfor carrying out CLIP that can be used in the present invention andpotentially obviate the need for a semipermeable “window” or windowstructure include utilizing a liquid interface comprising an immiscibleliquid (see L. Robeson, E. Samulski et al., Continuous three dimensionalfabrication from immiscible liquids, WO 2015/164234, published Oct. 29,2015; also published as US Patent Application Pub. No. US 2017/0228618on Feb. 2, 2017)), generating oxygen as an inhibitor by electrolysis(see I. Craven et al., WO 2016/133759, published Aug. 25, 2016), andincorporating magnetically positionable particles to which thephotoactivator is coupled into the polymerizable liquid (see J. Rolland,WO 2016/145182, published Sep. 15, 2016).

Other examples of methods and apparatus for carrying out CLIP include,but are not limited to: Batchelder et al., Continuous liquid interfaceproduction system with viscosity pump, US Patent Application Pub. No. US2017/0129169 (May 11, 2017); Sun and Lichkus, Three-dimensionalfabricating system for rapidly producing objects, US Patent ApplicationPub. No. US 2016/0288376 (Oct. 6, 2016); Willis et al., 3d printadhesion reduction during cure process, US Patent Application Pub. No.US 2015/0360419 (Dec. 17, 2015); Lin et al., Intelligent 3d printingthrough optimization of 3d print parameters, US Patent Application Pub.No. US 2015/0331402 (Nov. 19, 2015); and D. Castanon, StereolithographySystem, US Patent Application Pub. No. US 2017/0129167 (May 11, 2017).

In some cases, objects formed by additive manufacturing from resins asdescribed above have residual, unpolymerized or partially polymerized,resin on the surface thereof, which must be cleaned or washed from theobject, as described further below.

3. Wash Liquids.

Wash liquids that may be used to carry out the present inventioninclude, but are not limited to, water, organic solvents, andcombinations thereof (e.g., combined as co-solvents), optionallycontaining additional ingredients such as surfactants, chelants(ligands), enzymes, borax, dyes or colorants, fragrances, etc.,including combinations thereof. The wash liquid may be in any suitableform, such as a solution, emulsion, dispersion, etc.

In some preferred embodiments, where the residual resin has a boilingpoint of at least 90 or 100° C. (e.g., up to 250 or 300° C., or more),the wash liquid has a boiling point of at least 30° C., but not morethan 80 or 90° C. Boiling points are given herein for a pressure of 1bar or 1 atmosphere.

Examples of organic solvents that may be used as a wash liquid, or as aconstituent of a wash liquid, include, but are not limited to, alcohol,ester, dibasic ester, ketone, acid, aromatic, hydrocarbon, ether,dipolar aprotic, halogenated, and base organic solvents, includingcombinations thereof. Solvents may be selected based, in part, on theirenvironmental and health impact (see, e.g., GSK Solvent Selection Guide2009).

In some embodiments, the wash liquid can be an aqueous solution ofethoxylated alcohol, sodium citrate, tetrasodiumN,N-bis(carboxymethyl)-L-glutamate, sodium carbonate, citric acid, andisothiazolinone mixture. One particular example thereof is SIMPLE GREEN®all purpose cleaner (Sunshine Makers Inc., Huntington Beach, Calif.,USA), used per se or mixed with additional water.

In some embodiments, the wash liquid can be an aqueous solutioncomprised of 2-butoxyethanol, sodium metasilicate, and sodium hydroxide.One particular example thereof is PURPLE POWER™ degreaser/cleaner (AikenChemical Co., Greenville, S.C., USA), used per se or mixed withadditional water.

In some embodiments, the wash liquid can be ethyl lactate, alone or witha co-solvent. One particular example thereof is BIO-SOLV™ solventreplacement (Bio Brands LLC, Cinnaminson, N.J., USA), used per se ormixed with water.

In some embodiments, the wash liquid consists of a 50:50 (volume:volume)solution of water and an alcohol organic solvent such as isopropanol(2-propanol).

Examples of hydrofluorocarbon solvents that may be used to carry out thepresent invention include, but are not limited to,1,1,1,2,3,4,4,5,5,5-decafluoropentane (Vertrel® XF, DuPont™ Chemours),1,1,1,3,3-Pentafluoropropane, 1,1,1,3,3-Pentafluorobutane, etc.

Examples of hydrochlorofluorocarbon solvents that may be used to carryout the present invention include, but are not limited to,3,3-Dichloro-1,1,1,2,2-pentafluoropropane,1,3-Dichloro-1,1,2,2,3-pentafluoropropane, 1,1-Dichloro-1-fluoroethane,etc., including mixtures thereof.

Examples of hydrofluorether solvents that may be used to carry out thepresent invention include, but are not limited to, methylnonafluorobutyl ether (HFE-7100), methyl nonafluoroisobutyl ether(HFE-7100), ethyl nonafluorobutyl ether (HFE-7200), ethylnonafluoroisobutyl ether (HFE-7200),1,1,2,2-tetrafluoroethyl-2,2,2-trifluoroethyl ether, etc., includingmixtures thereof. Commercially available examples of this solventinclude Novec 7100 (3M), Novec 7200 (3M).

Examples of volatile methylsiloxane solvents that may be used to carryout the present invention include, but are not limited to,hexamethyldisiloxane (OS-10, Dow Corning), octamethyltrisiloxane (OS-20,Dow Corning), decamethyltetrasiloxane (OS-30, Dow Corning), etc.,including mixtures thereof.

Other siloxane solvents (e.g., NAVSOLVE™ solvent) that may be used tocarry out the present invention include but are not limited to those setforth in U.S. Pat. No. 7,897,558.

In some embodiments, the wash liquid comprises an azeotropic mixturecomprising, consisting of, or consisting essentially of a first organicsolvent (e.g., a hydrofluorocarbon solvent, a hydrochlorofluorocarbonsolvent, a hydrofluorether solvent, a methylsiloxane solvent, or acombination thereof; e.g., in an amount of from 80 or 85 to 99 percentby weight) and a second organic solvent (e.g., a C1-C4 or C6 alcoholsuch as methanol, ethanol, isopropanol, tent-butanol, etc.; e.g., in anamount of from 1 to 15 or 20 percent by weight). Additional ingredientssuch as surfactants or chelants may optionally be included. In someembodiments, the azeotropic wash liquid may provide superior cleaningproperties, and/or enhanced recyclability, of the wash liquid.Additional examples of suitable azeotropic wash liquids include, but arenot limited to, those set forth in U.S. Pat. Nos. 6,008,179; 6,426,327;6,753,304; 6,288,018; 6,646,020; 6,699,829; 5,824,634; 5,196,137;6,689,734; and 5,773,403, the disclosures of which are incorporated byreference herein in their entirety.

4. Wash Methods and Apparatus.

Apparatus for washing parts produced by additive manufacturing areknown, and can be modified for use in the present invention inaccordance with known techniques. (see, e.g., U.S. Pat. Nos. 5,248,456;5,482,659, 6,660,208; 6,996,245; and 8,529,703). However, many such partwashers are not adapted to cleaning larger numbers of more diverse partshaving much more diverse material properties. Hence, overall wash speedis preferably accelerated by employing higher volume liquid exchangepumps, and/or pneumatic liquid exchange, rapid draining of fluids suchas by gravity-assist, more aggressive agitation, such as by spinning theobjects to be cleaned in the wash liquid (e.g., while still mounted onthe carrier plate on which they were produced), by including “dry”steps, such as by draining the wash liquid and spinning the object inair to centrifugally remove residual resin and wash liquid from theobject, optionally by re-immersing the object in the wash liquid andrepeating the wash program, etc. Additional agitation sources, such asultrasonic agitation, can also be provided.

5. Fixturing Apparatus and Methods.

As disintermediation has become important in simplifying supply chainsand other economic transactions, so to has the simplification ofassembly lines become important in manufacturing. Processes such as heatstaking, adhesive and/or sealant dispensing and curing, and vibration orultrasonic welding component parts together, add complexity and expenseto many manufacturing processes. The present invention allowssimplification of such processes by largely consolidating them with thebonding potential of the green parts and the heat curing step, by simplyfixing at least one additional component part to a green, additivelymanufactured, component part prior to heat curing.

A non-limiting example of a fixturing apparatus (200) for use in thepresent invention is schematically illustrated in FIG. 13. In general, afixturing station or apparatus may include an alignment assembly(typically at least one guide (such as an alignment jig (201)), clamp(including mechanical and suction clamps such as a vacuum table (202)),or combination thereof) for receiving and securing a first componentpart (32), operatively associated with a suitable joining assembly(e.g., a chuck such as a pneumatic chuck for stretching and releasing apart; a press (203) such as a robotic arm, a mechanical, hydraulic orpneumatic press, etc., optionally fitted with a vacuum chuck (204);etc., including combinations of the foregoing) for contacting at leastone additional component part (232) to the first part after the firstpart has been received or secured into the alignment assembly. Pressureacross the bonding surfaces (211) can be maintained throughout thefurther curing or baking process by any suitable means, such as byclamping fixtures that clamp the components together, by internallocking forces between the parts (such as by interference fit (214)), byweight applied to the bonding surfaces (including external weights, andweight intrinsic to the object itself), etc., including combinations ofthe foregoing. The amount of pressure applied across the bondingsurfaces will depend upon a variety of factors, such as the materialsbeing bonded, the shape and smoothness of the surfaces, whether or notre-shaping of the additively manufactured part during the further curingis desired, etc. but in general will be from one half of a pound persquare inch, or one pound per square inch, up to ten or twenty poundsper square inch (e.g., where no re-shaping is desired), or up to fiftyor one hundred pounds per square inch or more (e.g., where re-shaping ofthe additively manufactured component part during further curing isdesired).

Transfer of the component parts to and from the fixturing station can becarried out manually or with any suitable apparatus (such as a conveyor,shuttle, robotic arm, etc., including combinations thereof).

While the illustrative embodiment of FIG. 13 shows a press having avacuum chuck positioned over a clamp assembly, an alternate embodimentwould utilize a vacuum table fitted with an alignment jig positionedbeneath a press, or either between a pneumatic chuck configured tostretch and release an additively manufactured component part ontoanother component part.

Either the first component part or the additional component part (orboth) may be additively manufactured (e.g., by stereolithography, suchas by CLIP). Where additively manufactured, the component parts may beretained on the carrier platform on which they were additivelymanufactured, or separated therefrom.

In some embodiments, one of the component parts (e.g., the additionalpart) may be formed from a different material, and/or by a differenttechnique, than the additively manufactured component part. Examples ofsuitable materials include, but are not limited to, metals (includingmetal alloys; e.g., steel, bronze, brass, iron, nickel, titanium,aluminum, etc.), inorganic materials (e.g., glass, ceramic, etc.),carbon fiber (e.g., carbon fiber composites), polymers (e.g.,polycarbonate, polyethylene, etc.), and composites of the foregoing.Examples of suitable techniques include, but are not limited to,forging, casting, injection molding, machining, etc., includingcombinations thereof.

Numerous possible embodiments can be implemented, specific examples ofwhich include, but are not limited to the following:

Fixing, by pressing, two different additively manufactured partstogether. The different parts may be formed from different resins thathave compatible chemistries and thermal cure schedules, e.g., anelastomeric polyurethane to a rigid polyurethane.

Fixing, by pressing, connectors, such as threaded metal inserts, intocorresponding sockets in green, additively manufactured component part

Fixing, by pressing, a green lattice structure formed by additivemanufacturing on to one or more pre-formed, external, partial orcomplete, shell components, aluminum alloy, carbon fiber composites,etc.)

Fixing, by pressing, a green seal bead produced by additivemanufacturing onto a pre-fabricated part to establish a face seal onthat part.

Fixing, by stretching and releasing (e.g., with a pneumatic chuck) agreen seal bead produced by additive manufacturing onto a pre-fabricatedpart to establish a radial seal on that part.

Note that many of the foregoing techniques can, when desired, re-shapethe additively manufactured component part during the further curing orbaking step: For example, from a “green” configuration that is optimizedfor the additive manufacturing step, to a configuration that ispreferred for the finished composite article.

Fixing of component parts together may be carried out before or afterwashing of the additively manufactured part or parts (preferably afterwashing), and before or after other steps such as removal of supportsfrom additively manufactured parts.

In a preferred embodiment, fixing of components parts together iscarried out before a heating or baking step.

6. Further Curing (Baking) Methods and Apparatus.

Further curing of the parts can be carried out by any suitabletechnique, but is typically carried out by heating may be active heating(e.g., in an oven, such as an electric, gas, solar oven or microwaveoven, or combination thereof). Ovens (48) may be batch or continuous(conveyor) ovens, as is known in the art, although batch ovens are shownin the Figures herein for purposes of simplicity.

Conveyor ovens are in some embodiments preferred, including multi-zoneconveyor ovens and multi-heat source conveyor ovens, and associatedcarriers for objects that can serve to provide more uniform or regularheat to the object being cured. The design of conveyor heating ovens,and associated controls, are well known in the art. See, e.g., U.S. Pat.Nos. 4,951,648; 5,179,265; 5,197,375; and 6,799,712.

In some embodiments, the heating (baking) step or program is carried outat at least a first (oven) temperature and a second (oven) temperature,with the first temperature greater than ambient temperature, the secondtemperature greater than the first temperature, and the secondtemperature less than 300° C. (e.g., with ramped or step-wise increasesbetween ambient temperature and the first temperature, and/or betweenthe first temperature and the second temperature).

For example, the intermediate may be heated in a stepwise manner at afirst temperature of about 70° C. to about 150° C., and then at a secondtemperature of about 150° C. to 200 or 250° C., with the duration ofeach heating depending on the resin chemistry, size, shape, and/orthickness of the intermediate. In another embodiment, the intermediatemay be cured by a ramped heating schedule, with the temperature rampedfrom ambient temperature through a temperature of 70 to 150° C., and upto a final (oven) temperature of 250 or 300° C., at a change in heatingrate of 0.5° C. per minute, to 5° C. per minute. (See, e.g., U.S. Pat.No. 4,785,075).

In some embodiments, the oven may include a carousel or rotisserie forthe objects, and/or a convection element, to facilitate uniform heating,

In some embodiments, the oven may include a light source, such as anultraviolet light source, to further light cure components therein,during the heat curing stage.

In some embodiments, the oven may include a gas source configured topurge the oven with an inert gas (e.g., nitrogen, argon) during bakingof objects therein (to achieve depletion of ambient oxygen during bakingof parts) at an atmospheric, elevated, or reduced pressure level; inother embodiments, the oven may include a gas source (e.g., compressedoxgen; an oxygen generator or concentrator) configured to enrich theatmosphere in the oven with oxygen during baking of objects therein; instill other embodiments, the oven may include both of the aforesaid gassources. The choice of gas source and/or gas pressure, to achieve eitheroxygen depletion or oxygen enrichment during baking, may depend upon theparticular resin from which the objects are produced.

Ovens will generally include a vent duct, connected to a venting system.In some embodiments, the vent includes a sensor or detector fordetecting one or more vapors that are “out-gassed” from the objectsbeing baked therein, such as solvents and/or diluents. The detector maybe operatively associated with the systems described herein to providedata characterizing the objects, or provide an indication of when bakingis complete (which may automatically stop the bake cycle). In addition,the vent may include a build-up or “choke” detector, to alert the userwhen the vent or vent system has an undesirable level of depositsthereon.

7. Additional Peripheral Machines.

While the present invention is described primarily with reference topart washing machines, fixturing stations, and ovens as devicesperipheral to the additive manufacturing machines, other peripheralmachines may also be used.

For example, pre-production machines, including resin dispenser and/orblending machines (as separately noted) when not a. component of theadditive manufacturing machine itself, may be included. In someembodiments, the resin dispenser and/or blending machines may be mobileresin dispenser and/or blending machines delivering resins to a fleet ofadditive manufacturing machines on demand.

Other pre-production machines, or maintenance machines, may also beincluded in the systems described herein. For example, when aninterchangeable build plate (window or “cassette”) is used, periodiccleaning thereof may be performed (e.g., by immersing in and/orscrubbing with a suitable solvent, such as isopropanol, or the washliquids as described above). Such machines (71) may be implemented andautomated in like manner as the part washing machines described herein(or in some cases the part washing machine can also serve as a cassettecleaning machine).

Additional examples of post-production machines that can be incorporatedas peripheral apparatus in the systems and methods described hereininclude, but are not limited to, part penetrant bath apparatus (e.g.,for impregnating an additional polymerizable component into a part afteradditive manufacturing, but before further or subsequent cure), partcutting, grinding, and/or finishing machines (e.g., bead blasting,milling, tumbling, painting, etc.).

Support removal apparatus. In a particular example, and as included inthe embodiment of FIG. 10, a post-processing apparatus may be a supportremoval apparatus (220). Such an apparatus may include a part uniqueidentifier reader and/or a build plate unique identifier reader (221),configured to identify the particular part (33) received by theapparatus. Such an apparatus may further include a clamp, guide and/orother suitable alignment components (e.g., a pneumatic chuck (222) on aturn-table (223) including a turntable drive (227) as shown in FIG. 14),to positively orient the part (optionally but in some embodimentspreferably still mounted on the carrier plate (44)) in a knownorientation, in response to instructions from a controller (220′). Thecontroller may then be configured to select a tool from a range oftools, e.g., a cutting or grinding tool (224), such as a laser cutterfor fitting onto a robotic arm (225), as shown in FIG. 14, guide thetool to appropriate locations and activate the tool to a predefinedpower setting to remove support structures (226) based on the knownstructure and characteristics, such as hardness, strength, toughness,softening point, of the object and support structures, thus obviatingthe need for optical detection and recognition of supports during theirremoval (though such may still be included if desired).

8. Unique Identifiers and Readers.

“Unique identifier” and “unique identifier reader” as used herein referto components of an automatic identification and data capture system.Suitable unique identifiers include, but are not limited to, bar codes(including one-dimensional and two-dimensional bar codes), near fieldcommunication (NFC) tags, radio frequency identification (RFID) tags(including active, passive, and battery-assisted passive RFID tags),optical character recognition (OCR) tags and readers, magnetic stripsand readers, etc. A variety of such systems are known and described in,for example, U.S. Pat. Nos. 8,120,468; 8,526,910; 9,373,201; 9,562,429;9,576,476; 9,587,487; 9,589,428; and 9,595,058. Unique identifiers andtheir corresponding readers of various different types can be utilizedat various points in the integrated system described herein, asdiscussed further below.

9. Integrated Systems.

Non-limiting examples of integrated systems and methods encompassed bythe present invention are given in FIGS. 1-12 herein.

As shown in FIGS. 1A-1B, it will be appreciated that different uniqueidentifiers (101, 102, 103, 104, 105) can be used at different points inthe systems and methods described herein. For example, an NFC tag, RFIDtag, and/or bar code (101) may be most appropriate for placing on orassociating with the resin container when the resin is manufactured,with the associated reader operatively associated with a resin dispenseror supply (41) system into which the resin (31) will be loaded by theresin user. The resin manufacturer can optionally utilize an associatedreader, when the resin is manufactured, to enter into the database theresin type, batch ingredient data, and/or manufacturer identity (see,for example, FIGS. 2A-2B).

Similarly, where resin is dispensed into a movable build plate (42)(sometimes also referred to as a “window” or a “cassette”) that is thentransferred with the resin to an additive manufacturing machine, then anNFC tag, RFID tag, and/or bar code (102) might be most appropriate toassociate with that build plate or cassette, with the associated readerat the resin dispenser (41) and/or at the additive manufacturing machine(43) configured to capture the build plate identity, and associate itwith the resin data, in the database. Non-limiting examples of resindispense data include that set forth in FIG. 2C. Thus “specific resindata” may include, for example, resin type data and resin batch data(non-limiting examples of which are given in FIGS. 2A-2B), optionallysupplemented with resin dispense data (non-limiting examples of whichare given in FIG. 2C).

When parts or objects (32) are additively manufactured on a removablecarrier plate (44), the carrier plate may have its own appropriateunique identifier (103), such as an NFC tag, RFID tag, and/or bar code,with appropriate reader on the additive manufacturing machine (43) andthe washing machine (45), to record additive production data (see, forexample, FIG. 3).

Each part (32) produced on an additive manufacturing machine can alsohave its own unique identifier (104) (for example, a set of alphanumericcharacters and/or symbols appearing on a surface or other locationthereof), which can be imparted by any suitable technique, including, inthe apparatus controller, a routine for modifying each product geometrydata file just before and/or during part production, and recording theunique identifier in association with that part (along with, forexample, other resin and part production data). A non-limiting exampleof such a routine is given in FIGS. 4A-4B, and as discussed furtherbelow. In some embodiments, modifying the product geometry data file mayinclude incorporating the unique identifier into the product geometrydata file so that the unique identifier is structurally incorporated inthe manufactured part. As used herein, structurally incorporated meansthat the unique identifier is formed into the structure of the partduring manufacture, in contrast to a unique identifier that is addedpost-production. For example, the unique identifier may be included(e.g., formed raised and/or recessed) in a surface of the manufacturedpart. In some embodiments, the unique identifier may be incorporatedinternally in the structure of the manufactured part so that it may notbe immediately visible from an outer inspection of the part.

As noted previously, part washing machines (45) may be configured toexecute a variety of different wash programs (as may best suit objectsmade in particular configurations and/or from particular resins),non-limiting examples of which are given in FIG. 5. When the part is tobe washed on the carrier platform on which it was produced (as shown inFIG. 1), the washing machine can include an appropriate identifierreader for recording the part washed, and also recording part wash stepdata for that particular part (See, for example, FIG. 6). If the washprogram is not pre-set (as may be the case for higher volume through-putof similar parts), then the wash machine can be configured to select theappropriate wash program for each part, based on information in thedatabase on part configuration and/or resin type.

In some embodiments, the wash machine (45) can dynamically determine theappropriate wash program for a part based on reading the uniqueidentifier associated with that part. The appropriate wash program maybe based on the part geometry, part materials, and/or other informationretrieved using the unique identifier. In some embodiments, the washmachine may be configured to dynamically switch from a first washprogram for a first part to a second wash program for a second partbased on respective first and second unique identifiers associated withthe first and second parts. As used herein, dynamically switching a washprogram means that characteristics of a wash program (e.g., intensityand/or duration) used by a wash machine may be modified withoutadditional intervention by an operator and/or programming based, inpart, on a unique identifier associated with the part being washed. Insome embodiments, the wash program being utilized by the wash machinefor a part may be determined at the time that a unique identifierassociated with the part is read by the appropriate identifier readerand compared to a database containing washing information for the givenpart.

In like manner, ovens (48) may be configured to execute a variety ofdifferent bake programs (again as may best suit objects made inparticular configurations and/or from particular resins). Here, the partmay be removed from its carrier platform (particularly if the NFC tag isnot heat resistant), but can be moved on a transfer table to a transfertray (47), where the transfer tray includes a more heat-stable uniqueidentifier (such as a bar code) (105), and the transfer table includes areader for both the carrier plate and the transfer tray (to associate inthe database the particular part with a particular tray), and the oven(48) can include a reader and/or scanner for the transfer tray uniqueidentifier (to associate, in the database, oven data with eachparticular tray, and hence to each particular part). Of course, multipleparts may be included on each tray, and other formats can be employed.For example, a sacrificial unique identifier (such as an NFC tag) can befastened to or associated with the part as it enters the oven, andalthough destroyed during the bake program, can still be utilized toassociate in the database the particular part with a particular oven,bake program, and operator, or other cure step information (see, forexample, FIG. 8). As with the washer, the oven may be configured toexecute a variety of different cure (particularly bake) program options,as shown in FIG. 7. If the bake program is not pre-set (as may again bethe case for higher volume through-put of similar parts), then the ovencan be configured to select the appropriate bake program for each part,based on information in the database on part configuration and/or resintype. In some embodiments, as discussed herein with the wash machine,the appropriate bake program for a part may be dynamically selected atthe time of baking based on the unique identifier associated with thepart that is read or otherwise accessed by the oven. In someembodiments, the oven may be configured to switch between a first set ofcuring options for the oven (see, e.g., FIG. 7) and a second set ofcuring options based the unique identifier associated with a given part.

In some embodiments, when preparing a part for curing, one or more partsmay be selected for simultaneous curing based, in part, on the uniqueidentifier for the respective parts. For example, when transferringparts from a carrier platform to a transfer tray, it may be determined,based on the unique identifiers for the parts, that one or more partsshare a curing configuration. In such a circumstance, the parts sharingthe curing configuration may be combined, such as by including the partson a same transfer tray or loading the parts separately into the oven ata same time, so that they may be cured simultaneously. In someembodiments, for example, when curing follows washing, a systemcontroller may identify parts which share curing configurations during awashing step (or other step which precedes curing) and may proactivelyschedule simultaneous curing for one or more parts. In some embodiments,an order in which parts are cured may not match an order in which partsare washed and/or manufactured, as parts are moved ahead or behind inorder to combine parts for curing. Such a combination of parts may allowthe manufacturing process to dynamically schedule curing so as to moreefficiently utilize curing equipment by combining parts which cure for asimilar amount of time at a similar temperature.

And again in like manner, in a support removal station such asschematically illustrated in FIG. 14, a tool mounted on a robotic armmay be guided to separate supports from the part (e.g., by cutting)through a suitable controller based on the known geometry of the part,as recognized at the support removal station by a unique identifierreader for either the part itself, or the carrier plate on which thepart was produced.

Where parts have a unique identifier formed thereon, such as analphanumeric and/or symbol indicator as noted above, washers, ovens, orother peripheral machines can simply include a camera for recording thatinformation from a particular part, to which it can be added to thedatabase, in addition to or as an alternative to some of the options forunique identifiers described above. In some embodiments, the uniqueidentifier may be formed on a portion of the part that is removed by thesupport removal station. In some embodiments, the unique identifier maybe formed on a portion of the part that remains after manufacturing. Insome embodiments, the unique identifier may include a combination ofsegments, some of which are removed by the support removal station andsome of which remain on the part after manufacturing.

Part unique identifiers. As noted above, a part unique identifier may beimparted to a part by a system as described in FIGS. 4A-4B. Such aunique identifier may be physically formed on the surface or otherlocation of the part, chemically or photochemically formed on or withinthe part, or by any other suitable technique. The unique identifier maybe arbitrary (e.g., simply a sequential or non-sequential numbering ofthe part), or may include specific information about the manufacturingprocess of the part. Examples of such specific information that may beincluded within a part of a unique identifier include, but are notlimited to:

(A) Additive manufacturing device (or “printer”) specific identity;

(B) Project number (i.e., a common number assigned to all similar orrelated parts);

(C) Print number (i.e., a number uniquely assigned to one specificpart);

(D) Build platform and/or window cassette position identity (i.e., anindication of the specific location on a “window” on which a particularpart was produced, particularly useful when multiple parts areconcurrently produced at the same time on the same build platform);

(E) Window cassette unique identity;

(F) Date of production.

(G) Resin type and/or identity

For example, in one embodiment, the part unique identifier may comprisea set of characters including A-B-C-D as defined above. In anotherembodiment, the part unique identifier may comprise a set of charactersincluding C-E-F, as defined above. In some embodiments, the part uniqueidentifier may be a sequence of alphanumeric characters and/or symbolsfrom which A-G, as defined above, may be retrieved from a database usingthe sequence of alphanumeric characters and/or symbols. Numerouscombinations of the foregoing, or other characteristics, will beapparent, and specific embodiments will depend upon the field and use ofthe particular part being made.

FIG. 4A is a flow chart schematically illustrating one process ofassigning and generating an individual object with a unique identifierfor that object, by additive manufacturing. In some embodiments, theobject may be a part to be manufactured by additive manufacturing. Forexample, as illustrated in FIG. 4A, a process for assigning andgenerating an individual object with a unique identifier may include, asan input, initial object data. The initial object data may be, forexample, a part geometry file or other set of instructions forgenerating a part by additive manufacturing. In addition, the processmay include a unique identifier generator configured to generate aunique identifier. As used herein, “unique” does not necessarily meanthat the identifier is universally unique. For example, a uniqueidentifier may be unique to a given manufacturer, a given part, a givenmanufacturing facility, etc. As used herein, a unique identifier is onein which a given part may be uniquely identified as determined by theparticular manufacturing circumstances. The unique identifier generatormay, in some embodiments, include a software program configured togenerate a unique identifier based on one or more characteristics of amanufactured part, as discussed herein.

For a particular manufactured part, the initial object data (111) forthe part may be combined with a unique identifier from the uniqueidentifier generator (112) to generate individual object data. Theindividual object data may, for instance, identify a particularmanufactured instance of a part described by the initial object data.Once generated, the individual object data may be recorded in a database(114). Future operations performed on the part during, and beyond,manufacturing may be associated with the individual object data. In someembodiments, the individual object data may include a unique sequence ofalphanumeric characters and/or symbols. In some embodiments, dataassociated with the individual object during manufacturing may be storedin the database associated with the unique sequence of alphanumericcharacters and/or symbols. For example, after generating the individualobject data for the part, the part may be manufactured (115). Asdiscussed herein, during manufacturing of the part, data associated withthe manufacturing process may be stored in the database and associatedwith the individual object data.

FIG. 4B is a flow chart of a particular embodiment of FIG. 4A. Asillustrated in FIG. 4B, an additive manufacturing process (300) for apart according to embodiments of the present invention may include aDesign portion (310), a Production portion (320), and a Recordingportion (330). During the Design portion (310), a set of initial objectdata (312) may be generated for the part to be manufactured. In someembodiments, the initial object data (312) may be generated using designsoftware, such as Computer-Aided Design (CAD) software, though thepresent invention is not limited thereto. Such CAD software may generatedata files which may be used during a manufacturing step to additivelymanufacture a part, such as via CLIP processes. In some embodiments, thepart may be represented in the initial object data (312) in variousformats, such as by a plurality of polygons (e.g., triangles) and/orother forms of boundary representation (B-reps), though the presentinvention is not limited thereto. In some embodiments, the initialobject data (312) may include data represented in a format used instereolithography, such as a .stl file.

During the Production portion (320), a unique identifier (322) may begenerated. In some embodiments, the unique identifier (322) may be aserial identification (ID) composed of alphanumeric numbers and/orsymbols. During a print preprocess step of the production, the initialobject data file (312) may be broken out in a set of part imagesequences (314). In some embodiments, this may be done by performing arasterization process on the initial object data file (312). Inaddition, the generated serial ID (322) may be broken out into a seriesof serial ID image sequences (324). These image sequences may be used byan additive manufacturing system to additively manufacture the partand/or the serial ID (322). In some embodiments, the part imagesequences (314) may be used to configure the additive manufacturingsystem to manufacture the part, and the serial ID image sequences (324)may be used to configure the additive manufacturing system tomanufacture the serial ID (322) (e.g., as a unique identifier). Thesystem controller may be configured to combine the part image sequences(314) and the serial ID image sequences (324) into at least one mergedimage sequence (326). The merged image sequence (326) may be used toconfigure the additive manufacturing system to manufacture the part(328) with the serial ID (322) on or within the part (328).

In order to generate the merged image sequence (326), the controller maybe configured to select a location on or within the part (328) to placethe serial ID (322). The location may be based on a geometry of thesurface of the part (328), a preferred location of the serial ID (322),and/or other characteristic of the part (328) and/or the manufacturingprocess. In some embodiments, the location for the serial ID (322) maybe included as part of the initial object data (312). For example, aninitially generated CAD file (312) may include a container (e.g., aplaceholder) for the to-be-generated serial ID (322). In someembodiments, the location may be dynamically determined. In someembodiments, the location for the serial ID (322) may be based oncriteria such as whether a given location is in a cosmetically criticalarea and/or whether a given location is accessible for inspection (e.g.,by human eyes and/or machine readers).

In some embodiments, generating the merged image sequence (326) mayinclude altering the original part geometry to place the serial ID (322)on or within the part (328). In some embodiments, the merged imagesequence (326) will differ from the part image sequence (314). In otherwords, a part (328) additively manufactured from the merged imagesequence (326) will differ from a part additively manufactured from thepart image sequence (314) (e.g., will contain the serial ID (322) on orwithin the part (328)).

During a Recording portion (340) of the process, the generated serial ID(322) may be uploaded (332) to a database (342). Subsequent operationsrelated to the part (328) may be associated in the database with (342)the generated serial ID (322), as discussed herein. For example, theadditive manufacturing process may manufacture the part (328) based onthe merged image sequence (326). While manufacturing the part (328),data associated with the manufacturing process may be recorded in thedatabase (342), associated with the serial ID (322) (e.g., as a uniqueidentifier) generated for the part (328). In such a way, data associatedwith the manufacturing of the part (328) such as, for example, printerconfiguration, resin configuration, etc. may be associated with the part(328) for later retrieval (344). As illustrated in FIG. 4B, recordeddata associated with the part (328) may be collected prior tomanufacturing the part (328) (e.g., during pre-production) and/or duringmanufacture. In some embodiments, recording can continue aftermanufacturing of the part, such as the recording of information relatedto shipment of the part (328), sale of the part (328), and/or customerfeedback associated with the part (328) (see FIG. 11).

System architecture. Non-limiting examples of system architectures aregiven in FIGS. 9-11. Nevertheless, it will be appreciated that any of avariety of different architectures can be employed. Controllers (41′,43′, 45′, 48′, 60′, 150′, 170′, 200′, 220′) can be a general purposecomputer dedicated to, or on board, a particular apparatus; a localgeneral purpose computer operatively associated with a group of machinesvia a local area network (or metropolitan area network) (see, forexample, FIG. 9A); a remote general purpose computer operativelyassociated with machines via a wide area network or internet connection(see, for example, FIG. 10; system 160); and combinations thereof (forexample, organized in a client-server architecture and/or distributedarchitecture).

Peripheral devices for data entry and display can be implemented in anyof a variety of ways known in the art, including typical keypad entry,video display, and printing apparatus (152, 173), as well as graphicaluser interfaces such as touch-pads, touch-screens and the like,including smart-phone touch screens.

The controller may use hardware, software implemented with hardware,firmware, tangible computer-readable storage media having instructionsstored thereon, and/or a combination thereof, and may be implemented inone or more computer systems or other processing systems. The controllermay also utilize a virtual instance of a computer. As such, the devicesand methods described herein may be embodied in any combination ofhardware and software that may all generally be referred to herein as a“circuit,” “module,” “component,” and/or “system.” Furthermore, aspectsof the present invention may take the form of a computer program productembodied in one or more computer readable media having computer readableprogram code embodied thereon.

Any combination of one or more computer readable media may be utilized.The computer readable media may be a computer readable signal medium ora computer readable storage medium. A computer readable storage mediummay be, for example, but not limited to, an electronic, magnetic,optical, electromagnetic, or semiconductor system, apparatus, or device,or any suitable combination of the foregoing. More specific examples (anon-exhaustive list) of the computer readable storage medium wouldinclude the following: a portable computer diskette, a hard disk, arandom access memory (RAM), a read-only memory (ROM), an erasableprogrammable read-only memory (EPROM or Flash memory), an appropriateoptical fiber with a repeater, a portable compact disc read-only memory(CD-ROM), an optical storage device, a magnetic storage device, or anysuitable combination of the foregoing. In the context of this document,a computer readable storage medium may be any tangible medium that cancontain, or store a program for use by or in connection with aninstruction execution system, apparatus, or device.

A computer readable signal medium may include a propagated data signalwith computer readable program code embodied therein, for example, inbaseband or as part of a carrier wave. Such a propagated signal may takeany of a variety of forms, including, but not limited to,electro-magnetic, optical, or any suitable combination thereof. Acomputer readable signal medium may be any computer readable medium thatis not a computer readable storage medium and that can communicate,propagate, or transport a program for use by or in connection with aninstruction execution system, apparatus, or device. Program codeembodied on a computer readable signal medium may be transmitted usingany appropriate medium, including but not limited to wireless, wireline,optical fiber cable, RF, etc., or any suitable combination of theforegoing.

In some embodiments, the controller may include at least one processor.The at least one processor of the controller may be configured toexecute computer program code for carrying out operations for aspects ofthe present invention, which computer program code may be written in anycombination of one or more programming languages, including an objectoriented programming language such as Java, Scala, Smalltalk, Eiffel,JADE, Emerald, C++, C#, VB.NET, or the like, conventional proceduralprogramming languages, such as the “C” programming language, VisualBasic, Fortran 2003, COBOL 2002, PHP, ABAP, dynamic programminglanguages such as Python, PERL, Ruby, and Groovy, or other programminglanguages.

The at least one processor may be, or may include, one or moreprogrammable general purpose or special-purpose microprocessors, digitalsignal processors (DSPs), programmable controllers, application specificintegrated circuits (ASICs), programmable logic devices (PLDs),field-programmable gate arrays (FPGAs), trusted platform modules (TPMs),or a combination of such or similar devices, which may be collocated ordistributed across one or more data networks.

Data storage or memory (151, 171) of the controller can be on separate(volatile and/or non-volatile) memory devices located locally orremotely, partitioned sections of a single memory device, etc.,including combinations thereof (e.g., a remote back-up memory inaddition to a local memory). For example, the database referred toherein may be one or more databases stored locally to the controller orremote. In some embodiments, the database may be remotely accessible bythe controller.

Since multiple different manufacturers may use resins from a commonsupplier, a higher level of system integration may be desirable, asshown in FIG. 11. Here, the resin supplier (“A” shown, but additionalmay be included) can enter resin type and batch data into a masterdatabase (182, 183), which can be shared across multiple separateadditive manufacturing systems (“A,” “B,” and “C” shown, but additionalmay be included). Also, since end user feedback (either survey solicitedor voluntary) or further chain-of-sale information may be useful to themanufacturer, input/output devices (185, 186) (such as a smart phoneapplication, or a program running on a remote computer, etc.) can beincluded for adding to the database customer feedback and useinformation on a particular part ((end user “A” shown, but additionalcan be included). A report from such a system for a particular part mayinclude some or all of the information fields shown in FIG. 12. Sinceproduct configuration data (e.g., .stl files) or other manufacturinginformation (in some cases, production program, wash program, and/orbake program) can be proprietary to a particular manufacturer, thecontrollers can be configured so that reports for other participantssuch as end users, or as a master report containing information acrossdifferent manufacturers, excludes or automatically redacts thatinformation. Or, that information can be partitioned or separated indata storage so that it is never available for such end user or masterreports in the first instance.

Robotics. Transfer of workpieces such as transfer of the carrierplatform from the additive manufacturing apparatus to the washapparatus, transfer of the carrier platform from the wash apparatus tothe curing apparatus, transfer of the build plate from an additivemanufacturing apparatus to a cleaning apparatus, transfer of a resincartridge to an additive manufacturing apparatus, etc., may be carriedout manually, robotically (60), or combinations thereof. Systems forrobotic transfer can be implemented in accordance with known techniquesemployed in robotic manufacturing systems, or variations thereof thatwill be apparent to those skilled in the art. See, e.g., U.S. Pat. Nos.6,627,016; 6,694,224; 7,146,705; 8,651,160; 8,668,423; and 9,351,569.

While FIGS. 9A-11 describe systems utilizing a CLIP additivemanufacturing apparatus, recall that any suitable additive manufacturingapparatus can be used in the systems described herein, including but notlimited to other apparatus for bottom-up or top-down stereolithography,as discussed generally in section 2 above. Where a CLIP apparatus isemployed, some such apparatus employ atmospheric oxygen as an inhibitorof polymerization, and others employ an oxygen source (e.g., a gasenriched in oxygen) as the inhibitor of polymerization. The oxygensource may be compressed gas enriched in oxygen, an oxygen generator, anoxygen concentrator, or any other suitable supply, located or associatedwith each machine, or a shared source (411) such as shown in FIG. 9B orbottled oxygen on each machine, a distributed oxygen supply. Similarly,since the oxygen concentration in resin during CLIP apparatus operationmay be sensitize to fluctuations in atmospheric pressure, a barometricsensor (412) may be associated with each machine (as also shown in FIG.9B), or a shared sensor may be employed, or atmospheric oxygen oratmospheric pressure data obtained via an external source such as theworld wide web. Such data may be used by each CLIP apparatus at aparticular location to further enrich or deplete oxygen supplied to eachmachine, such as by metering the flow of enriched oxygen gas to thebuild surface, window or window cassette of a particular apparatus. Seegenerally B. Feller, D. Moore et al., PCT Application Pub. No.WO/2018/006029 and B. Feller, D. Moore et al., PCT Application Pub. No.WO/2018/006018.

The foregoing is illustrative of the present invention, and is not to beconstrued as limiting thereof. The invention is defined by the followingclaims, with equivalents of the claims to be included therein.

1. An integrated additive manufacturing system, comprising: (a) at leastone resin supply; (b) a plurality of additive manufacturing machines onwhich parts may be produced, each of said additive manufacturingmachines operatively associated with said at least one resin supply; and(c) at least one peripheral machine operatively associated with each ofsaid additive manufacturing machines and said at least one resin supply,wherein said at least one peripheral machine comprises a part fixturingapparatus.
 2. The system of claim 1, wherein said at least one resinsupply comprises a single-use resin supply or a bulk resin supply, eachof which can be associated with either one of or a plurality of saidadditive manufacturing machines, and each of which can optionallyinclude an automated resin feed system configured to supply resin to oneof, or a plurality of, said additive manufacturing machines.
 3. Thesystem of claim 1, wherein said at least one peripheral machinecomprises: at least one part post-production machine, such as at leastone of a part washing machine, a part penetrant bath apparatus, a partoven, a part cutting, grinding, and/or texturing machine, a supportremoval apparatus, a part painting machine, or a combination thereof;and/or at least one maintenance machine configured to maintain orreplace a component of said additive manufacturing machines, such as abuild plate cleaning machine.
 4. The system of claim 1, wherein said atleast one peripheral machine further comprises a part washing machine.5. The system of claim 1, further comprising: (d) a database operativelyassociated with each of said plurality of additive manufacturingmachines, said database configured to record part configuration data foreach part produced on each additive manufacturing machine.
 6. The systemof claim 5, wherein: said database is further configured to containspecific resin data for each of a plurality of different resins; said atleast one resin supply comprises a resin container having a resintherein and a resin unique identifier operatively associated therewith,said resin unique identifier associated with specific resin data for thecontained resin; and each of said plurality of additive manufacturingmachines comprises a resin unique identifier reader operativelyassociated therewith and a resin reservoir configured to receive resinfrom said resin container; with each of said plurality of additivemanufacturing machines configured to carry out a part production processwith said resin based on both part configuration data (e.g., an .stlfile) and said specific resin data.
 7. The system of claim 5, whereinsaid at least one peripheral machine further comprises a part washingmachine, and wherein: each of said additive manufacturing machinesincludes a releasable carrier plate on which a part is produced fromsaid resin, each of said carrier plates having a carrier plate uniqueidentifier operatively associated therewith; said database is furtherconfigured to record both part configuration data and resin data, andoptionally time of production, for each part produced on each carrierplate; said part washing machine includes a carrier plate uniqueidentifier reader operatively associated therewith; said part washingmachine is configured to select and carry out a part washing process oneach part from a plurality of different part washing processes(optionally but preferably while each said part remains on the carrierplate on which the part was produced) based on: (i) part configurationdata, (ii) specific resin data, or (iii) both part configuration dataand specific resin data; and optionally but preferably with saiddatabase configured to record washing process data, and optionally butpreferably time of wash, for each part washed in said part washingmachine.
 8. The system of claim 7, wherein: at least one of saidperipheral machines is configured to releasably secure said carrierplate.
 9. The system of claim 7 any preceding claim, further comprising:(e) an oven operatively associated with each said additive manufacturingmachine; optionally with said oven configured to select and carry out abaking process on each part from a plurality of different bakingprocesses (optionally while each said part remains on the carrier plateon which the part was produced) based on: (i) part configuration data,(ii) specific resin data, or (iii) both part configuration data andspecific resin data; and optionally with said database configured torecord baking process data, and optionally time of bake, for each partbaked in said oven.
 10. The system of claim 5, each of said additivemanufacturing machines configured to apply a part unique identifier toeach part produced thereon; with said database further configured torecord said part unique identifier from each of said additivemanufacturing machines.
 11. The system of claim 5, each of said additivemanufacturing machines including an interchangeable build plate, saidbuild plate including an optically transparent member and a build plateunique identifier, with each of said plurality of additive manufacturingmachines further including a build plate unique identifier reader; andwith said database further configured to record build plate data foreach part produced on each of said plurality of additive manufacturingmachines.
 12. The system of claim 1, wherein the part fixturingapparatus is configured to fix a first part to an additional part toform a composite article, the system further comprising a curingapparatus configured to cure said composite article, with said firstpart and said additional part pressed against one another during saidcuring with force sufficient to adhere one to the other.
 13. The systemof claim 12, wherein said first part is reshaped during the a curingoperation of the curing apparatus. 14-23. (canceled)
 24. An integratedmethod for producing and baking parts by additive manufacturing,comprising: (a) providing a manufacturing system including a pluralityof additive manufacturing machines operatively associated with an oven,and optionally with a part washing machine, with said oven configured toexecute a plurality of different bake programs; (b) generating at leastone part on each of said plurality of additive manufacturing machines toproduce a plurality of parts to optionally be washed, each part of saidplurality of parts produced from a resin and from part configurationdata; (c) optionally washing each of said plurality of parts in saidpart washing machine; (d) optionally, but in some embodimentspreferably, fixing each said plurality of parts as a first part to arespective additional part to form a composite article of each thereof;and then (e) baking each of said plurality of parts, sequentially orsimultaneously in said oven, with each of said parts baked in accordancewith a bake program selected or configured based on (i) partconfiguration data, (ii) specific resin data, or (iii) both partconfiguration data and specific resin data.
 25. The method of claim 24,wherein said step of washing each of said plurality of parts is includedand carried out with the same wash liquid in accordance with pluralityof consecutive wash programs for each part, each wash program selectedor configured based on: (i) part configuration data, (ii) specific resindata, or (iii) both part configuration data and specific resin data. 26.The method of claim 24, wherein said oven comprises a batch oven(optionally including a lock assembly and/or an alarm, and said bakingstep optionally further includes locking said oven for the duration ofsaid bake program, and/or activating said alarm upon deviation by saidoven from said bake program).
 27. The method of claim 24, wherein saidoven comprises a continuous process (conveyor) oven (optionallyincluding a temperature monitor, and said oven optionally includes ashut-down and/or alarm configured to operate upon deviation by said ovenfrom said bake program).
 28. The method of claim 24, further comprisingrecording at least one, any combination, or all of oven identity, bakeprogram, day of bake, time of day of bake, and/or oven operator,interval between additive production and bake, and/or interval betweenwash and bake, and/or wash machine operator, in association with eachpart.
 29. The method of claim 24, wherein: said fixing step (d) and saidbaking step (e) are both included so that said parts are further curedas composite articles, and said composite articles are further curedwith said first part and said additional part pressed against oneanother during said baking step with force sufficient to adhere one tothe other.
 30. The method of claim 29, wherein said first part isreshaped during said baking step.
 31. A method of making a compositearticle by additive manufacturing, comprising: (a) producing a firstpart from a dual cure resin by additive manufacturing; (b) washing saidfirst part with a solvent; then (c) fixing said first part to anadditional part to form a composite article; and then (d) further curingsaid composite article, with said first part and said additional partpressed against one another during said further curing step with forcesufficient to adhere each to the other.
 32. The method of claim 31,wherein said force is imparted at least in part by interference fitbetween said first part and said additional part.
 33. The method ofclaim 31, wherein said force is imparted at least in part by a removableclamp or fixture forcing said first part and said additional parttogether.
 34. The method of claim 31, wherein said force is imparted atleast in part by weight applied to bonding surfaces of said compositearticle.
 35. The method of claim 31, wherein said first part is reshapedduring said baking step.